Portable air compressor tool carrier

ABSTRACT

The present invention is directed to a portable air compressor assembly including a tool carrier. In an embodiment, the portable air compressor assembly includes an air tank for storing compressed air and a compressor for supplying compressed air to the air tank. Further, a frame is coupled to the air tank and compressor providing an area for which the air tank and compressor may be mounted. In such embodiment, a pair of wheels are pivotally mounted to the frame allowing for inclined transportation of the air compressor assembly. In an embodiment, the tool carrier assembly includes a pan support coupled to the frame for providing a support surface for an air compressor accessory and work material. In addition, a tool support is coupled to the pan support for providing an additional support surface for the air compressor accessory and work material. The tool support includes at least one strap.

CROSS-REFERENCE TO RELATED DOCUMENTS

The present application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 60/540,755, entitled “Air Compressor Tool Carrier,” filed Jan. 30, 2004 which is herein incorporated by reference in its entirety. The present application is a continuation-in-part under 35 U.S.C. § 120 of U.S. applications Ser. Nos. 10/410,129, filed on Apr. 9, 2003, 29/179,391, filed on Apr. 9, 2003, and 10/444,708, filed on May 23, 2003. The present application incorporates the following applications by reference in their entirety: U.S. application Ser. No. 10/410,129, filed Apr. 9, 2003; U.S. Application Ser. No. 29/179,391, filed Apr. 9, 2003; U.S. Provisional Application Ser. No. 60/469,645, filed May 12, 2003; U.S. application Ser. No. 10/444,708, filed May 23, 2003; China Patent Serial No. 2L 03358051, filed Aug. 27, 2003; China Application Serial No. 03156352.X, filed Sep. 4, 2003; U.S. Provisional Application Ser. No. 60/517,644, filed Nov. 5, 2003; and U.S. application Ser. No. 10/982,395, filed Nov. 5, 2004.

FIELD OF THE INVENTION

The present invention relates generally to the field of portable air compressors, and more particularly to a tool carrier for a portable air compressor.

BACKGROUND OF THE INVENTION

Portable air compressors, because of their mobility, are widely used in household and industrial applications for operating air-powered tools such as nailers, socket driving tools, material shapers, sanders, sprayers, inflation chucks, and the like. Consequently, portable air compressors require various accessories such as fittings, nozzles, hoses or the like. Transportation of air compressor components and other materials necessary to perform a particular job is often cumbersome due to the lack of a storage compartment on the air compressor assembly. Such limitation causes the user to have to carry components separate from the air compressor assembly as well as find storage space for such components once at the worksite. Further, since these accessories are detachable, if a user is required to store such parts separately, the accessories may become lost, and actual operational difficulties may arise. For example, it is not uncommon for an operator to first transport a portable air compressor for a long distance to a worksite and then to realize that the desired operation may not be performed because the necessary accessory was not brought to the worksite. This may result in work time losses, added labor cost, and the like. Moreover, the benefit of the mobility of the portable air compressor may be offset by the operator's inability to access the desired accessory.

Thus, it would be advantageous to provide a portable air compressor assembly with a tool carrier for carrying and storing air compressor accessories such as air hoses, power cords, tools, and the like.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a portable air compressor assembly including a tool carrier which may be used to store and transport air compressor accessories, components, and work material. In exemplary embodiments, the portable air compressor assembly includes a compressor for supplying compressed air to an air storage tank and the compressor is mounted in a frame. In such embodiment, a pair of wheels are pivotally mounted to the frame allowing for inclined transportation of the air compressor assembly. In an embodiment, the tool carrier assembly includes a pan support coupled to the frame for providing a support surface for an air compressor accessory and work material. In addition, a tool support is coupled to the pan support for providing an additional support surface for the air compressor accessory and work material. The tool support includes at least one strap.

In specific embodiments of the invention, the tool support may include a rack and/or a back support. Further, in one embodiment, the at least one strap includes a system of flexible straps formed of material selected from the group consisting of plastic, rubber, nylon, vinyl, and hook and loop fastening material. In further exemplary embodiments, a nylon mesh material may be coupled to the system of flexible straps.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:

FIGS. 1A and 1B are isometric views illustrating a portable air compressor assembly including a tool carrier in accordance with an exemplary embodiment of the present invention, wherein the tool carrier includes a pan support and a tool support;

FIG. 1C is an isometric view illustrating a portable air compressor assembly including a tool carrier in accordance with the present invention, wherein the tool carrier includes a hose reel;

FIGS. 2A and 2B are isometric views illustrating a portable air compressor assembly including a tool carrier in accordance with the present invention, wherein the tool carrier includes a rack;

FIGS. 3A and 3B are isometric views illustrating a portable air compressor including a tool carrier in accordance with the present invention, wherein the tool carrier includes a system of flexible straps or pulls;

FIG. 4A is an isometric view illustrating a portable air compressor including a tool carrier in accordance with the present invention, wherein the tool carrier is an open top molded box;

FIG. 4B is an isometric view of the tool carrier illustrated in FIG. 4A, wherein the open top molded box is mounted to a pan support; and

FIG. 5 is an isometric view illustrating a portable air compressor assembly including a tool carrier in accordance with the present invention, wherein the tool carrier is included within a pancake-style air compressor assembly.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.

Referring specifically to FIGS. 1A and 1B, an air compressor assembly 100 including a tool carrier 102 in accordance with an exemplary embodiment of the present invention is shown. The air compressor assembly 100 includes an air storage tank 104 for storing compressed air, an air compressor 106 for supplying compressed air to the air storage tank 104, and a manifold assembly 108 for controlling and distributing compressed air from the air compressor assembly 100 to one or more air-powered tools. In exemplary embodiments, the manifold assembly 108 may be removable.

As shown in FIGS. 1A and 1B, the air compressor assembly 100 is equipped with a frame or roll cage 110 that at least substantially surrounds the air storage tank 104 and the air compressor 106 providing a surface area to which various air compressor assembly 100 components may be mounted. In such embodiment, the roll cage 110 is formed of hollow tubes shaped of steel, metal, plastic, and the like.

In the exemplary embodiment, the air storage tank 104 as well as the manifold assembly 108 may be mounted to the roll cage 110 (e.g., welded, or the like). As shown in FIGS. 1A and 1B, the manifold assembly 108 may be mounted to the roll cage 110 via fasteners such as screws, bolts, and the like. During use, the manifold assembly 108 may be removed from the roll cage 110 and coupled thereto via a single air hose so the manifold assembly 108 may be utilized at locations remote from the air compressor assembly 100.

Two or more wheels 112 and a handle assembly 114 may be mounted to the roll cage 110 for allowing an operator to easily lift and transport the air compressor assembly 100 between worksites. It is contemplated that the handle assembly 114 may be mounted to the roll cage 110 by welding or through the use of fasteners such as screws, nuts, bolts, and the like, to the roll cage 110. In exemplary embodiments, the handle assembly 114 may include a grip for easy grasping. It is contemplated that the handle assembly 114 may be extendable as disclosed in U.S. Provisional Application Ser. No. 60/517,644, filed on Nov. 5, 2003 and U.S. application Ser. No. 10/982,395, filed on Nov. 5, 2004. The two wheel 112 configuration allows a user to control assembly mobility. For example, in order to move the air compressor assembly 100 to a desired location, a user extends the handle assembly 114 and tilts air compressor assembly 100 backwards so that the weight of the assembly 100 rests upon the two wheels 112. Upon reaching the desired location, a user may move the air compressor assembly 100 from a tilted position to one which is flush with the ground allowing a user to leave the assembly 100 without concern about any further movement. The extended handle assembly 114 may be retracted so to prevent the user from tripping over the handle assembly 114 while using the air compressor assembly 100.

As illustrated in FIGS. 1A and 1B, the tool carrier 102 may be mounted to the roll cage 110. In the exemplary embodiment shown, the tool carrier 102 includes a pan support 116 and a tool support 118. In the present embodiment, the tool support 118 includes a back support member. The pan support 116 may be welded to the roll cage 110. Alternatively, the pan support 116 may be mounted to the roll cage 110 through fasteners such as screws, bolts, and the like. Further, the tool support 118 may be secured to the pan support 116 via fasteners such as screws, bolts, and the like or alternatively, by welding the tool support 118 to the carrier support 116. The pan support 116 and the tool support 118 may be formed of metal such as steel, aluminum and the like, plastic, or any other suitable material known in the art. In addition, the pan support 116 may be stamped or formed to include raised portions. Such configuration may impart rigidity to the pan support 116 or assist in the holding of various air compressor accessories such as hoses, nozzles, and the like.

As shown in FIG. 1C, the tool support may be comprised of a hose reel assembly which is attached to the pan support 116. In such embodiment, the hose reel assembly allows at least one air compressor accessory (e.g. a hose) to be secured around the reel 120 as well as for the storage of additional air compressor accessories (e.g. nozzles, fittings, and the like) or necessary tools (e.g. wrenches, screwdrivers, etc.) and hardware (e.g. nails) necessary for a specific job inside the hose reel 122. For example, a user may equip the air compressor assembly 100 with a hose and job specific tools and components prior to leaving for a job-site. All of the components are then transported with the compressor assembly 100 ensuring that the user is able to commence work upon arrival and not wait for the separately transported components. The hose reel assembly may be formed of plastic, metal, and the like. Further, such assembly may be secured to the pan support 116 via welding or the use of fasteners including screws, nuts, bolts, and the like.

Referring now to FIGS. 2A and 2B, an air compressor assembly 200 is shown, wherein the tool carrier 210 includes a pan support 204 and a tool support including a rack 202 and a back support member 206. It is contemplated that the pan support 204 and the rack 202 may be welded to a frame or roll cage 208 encompassing an air compressor assembly 200 or secured via fasteners such as screws, bolts, and the like. Further, the back support member 206 may be secured to the pan support 204 via similar mechanisms. The tool carrier 210 components may be formed of metal, plastic, or the like. In addition, a cover 212 may be provided to surround the rack 202 providing additional methods for securing the desired tools within the tool carrier assembly 200.

In exemplary embodiments of the present invention, the cover 212 is made of fabric. For example, the cover 212 may be a net or web formed of durable knit fabrics such as nylon, and the like, and may have small holes that are of sufficient size to capture small parts such as small tools and generally used air compressor accessories (e.g. nozzles, fasteners, and the like) while allowing dirt, debris, and water to escape. In another exemplary embodiment of the present invention, the cover 212 may be made of plastic. For example, the cover 212 may be made of transparent or translucent plastic, allowing an operator to visually see the contents of the storage compartment from outside the compartment and/or preventing small parts from falling out. It is contemplated that the cover may be secured to the rack 202 via fasteners including hooks, snaps, hook and loop fastening material, and the like. Alternatively, the plastic cover may be secured to the rack 202 via fasteners including screws, nuts, and bolts, as well as adhesive (e.g. glue, tape, etc.).

The tool support of the tool carrier assembly 210 may further include a strap or pull to provide additional methods of securing air compressor components. In such embodiment, the strap may be formed of plastic, fabric (e.g. hook and loop fastening material), vinyl, rubber, and the like. For example, the strap may be secured to either the sides or the back of the rack 202. Further, in use, a user may place the desired item(s) onto the pan support 204 and then, secure the item(s) by pulling the strap over the item(s) and fastening the strap to the front of the pan support 204. The strap may be secured to the pan support 204 via fasteners including grommets, eyelets, hooks, ratchets, and the like. In additional embodiments, the strap may include an aperture allowing the strap to be secured to the pan support 204 by tying or inserting a fastener into the aperture. It will be appreciated that more than one strap may be utilized to secure the item(s) to the pan support 204.

Referring now to FIGS. 3A and 3B, a portable air compressor assembly 300 in accordance with a third embodiment of the present invention is described, wherein the tool carrier 302 includes a tool support with a system of a flexible pulls or straps 304 and a pan support 306 for securing tools, hoses, and the like, onto the pan support 306. In exemplary embodiments, the pulls 304 may be made of flexible material such as molded rubber or plastic or additional materials including nylon, elastic, vinyl, and the like. In this embodiment, the pulls 304 may further include a mesh netting 305 providing additional support to the components. The ends of the pulls 304 may include fastening material such as hook and loop fastening material, metal hooks, grommets, ratchets, and the like, to allow for attachment of the pulls 304 to a roll cage 308. In additional embodiments, the pulls 304 may include one or more apertures allowing the pulls 304 to be secured to the pan support 306 by tying or inserting a fastener into the aperture.

In the exemplary embodiment, the pan support 306 may be welded to a roll cage 308. Alternatively, the pan support 306 may be mounted to the roll cage 308 via fasteners such as screws, bolts, and the like. The pan support 306 may be formed of metal such as steel, aluminum and the like, plastic, or any other suitable material known in the art. In addition, the pan support 306 may be stamped or formed to include raised portions. Such configuration may impart rigidity to the pan support 306 or assist in the holding of various air compressor accessories such as hoses, nozzles, and the like.

In an exemplary embodiment, the pulls 304 are fastened to the upper edges of the pan support 306 allowing for a secure fit of such pulls 304. It is contemplated that alternative configurations of fastening the pulls 304 to the pan support 306 may be employed. During use, a user may place items to be secured onto the pan support. 306. The items may then be secured by fastening the pulls 304 to the pan support 306. It is contemplated that the instant pulls 304 may be implemented with other embodiments of the presently disclosed tool carrier (e.g. in the presence of a rack and a back support). It is further contemplated that the pulls 304 may be fastened to additional components within the air compressor assembly 300 including the roll cage 308.

Referring to FIGS. 4A and 4B, a portable air compressor assembly 400 in accordance with a fourth exemplary embodiment of the present invention is described. For example, as illustrated in FIG. 4A, the tool carrier 402 comprises an open top box comprised of molded plastic capable of receiving certain types of power tools and other supplies. For example, in the embodiment shown, the tool carrier 402 has a receptacle 404 for a nail gun and smaller items such as nails 406. It is understood that the present invention is not limited to the embodiments illustrated wherein the receptacle shape and size may be altered as needed to satisfy application requirement.

As illustrated in FIG. 4A, in one exemplary embodiment of the present invention, the tool carrier 402 is recessed into the air compressor assembly 400 by fastening the tool carrier 402 to a roll cage 408. The tool carrier 402 may be fastened to the roll cage 406 via fasteners including screws, nuts, bolts, straps or pulls, and the like. Utilization of straps or pulls for securing the tool carrier 402 to the roll cage 408 allows a user to easily remove the tool carrier 402 if so desired. It is contemplated that the straps or pulls may be formed of hook and loop fastening material, nylon, vinyl, or rubber material. It is further contemplated that the straps or pulls may include fasteners on their ends such as metal hooks, ratchets, and the like allowing for the attachment of the straps or pulls to the roll cage 408.

As illustrated in FIG. 4B, the air compressor assembly 400 includes a tool carrier 410 comprised of an a open top box which is placed on top of a pan support such as that disclosed in FIGS. 1A-3B. In such embodiment, the tool carrier 410 may be fastened to the roll cage 412 via fasteners including screws, nuts, bolts, straps or pulls, and the like. Utilization of straps or pulls for securing the tool carrier 410 to the roll cage 412 allows a user to easily remove the tool carrier 410 if so desired. It is contemplated that the straps or pulls may be formed of hook and loop fastening material, nylon, vinyl, rubber material, or the like. It is further contemplated that the straps or pulls may include fasteners on their ends such as metal hooks, ratchets, and the like allowing for the attachment of the straps or pulls to the roll cage 412.

In further exemplary embodiments of the tool carrier 410, an additional strap 414 or straps may be employed to secure the item(s) within the carrier 410. It is contemplated that the pulls or straps may be formed of hook and loop fastening material, nylon, elastic, vinyl, rubber, and the like.

Referring now to FIG. 5, an air compressor assembly 500 including a tool carrier 502 in accordance with a fifth exemplary embodiment of the present invention is provided. In FIG. 5, the air compressor assembly 500 includes a pancake-style air storage tank 504 for storing compressed air and an air compressor 506 for supplying compressed air to the air storage tank 504.

As shown in FIG. 5, the air compressor assembly 500 is equipped with a dolly frame 510 to which the air storage tank 504 and air compressor 506 may be mounted to allow for the assembly 500 to be easily transported. In such embodiment, the dolly frame 510 is formed of hollow tubes shaped of metal, plastic, and the like. Further, wheels 511 are mounted to the dolly frame 510 so that the air compressor assembly 500 may be transported on wheels. The two wheel 511 configuration allows a user to control assembly mobility. For example, in order to move the air compressor assembly 500 to a desired location, a user tilts the dolly frame 510 backwards so that the weight of the assembly 500 rests upon the two wheels 511. Upon reaching the desired location, a user may move the dolly frame 510 from a tilted position to one which is perpendicular with the ground allowing a user to leave the assembly 500 without concern about further movement.

As illustrated in FIG. 5, the tool carrier 502 may be mounted to the dolly frame 510 allowing for tools to be easily transported with the air compressor assembly 500 to a worksite. In an exemplary embodiment, the tool carrier 502 includes a pan support 512 and a tool support 514. In one embodiment, the support carrier member 512 is welded to the tool support 514. Alternatively, the pan support 512 is mounted to the tool support 514 via fasteners such as screws, bolts, and the like. In turn, the tool support 514 may be secured to the dolly frame 510 via fasteners such as screws, bolts, and the like or alternatively, by welding the tool support 514 to the dolly frame 510. The pan support 512 and the tool support 514 may be formed of metal such as steel, plastic, or any other suitable material known in the art. In addition, the pan support 512 may be stamped or formed to include raised portions. Such configuration may impart rigidity to the pan support 512 or assist in the holding of various air compressor accessories such as hoses, nozzles, and the like. Further, in an exemplary embodiment, the pancake-style air storage tank 504 may be mounted to the dolly frame 510 via welding or fasteners such as screws, bolts, and the like

In further exemplary embodiments, as described above, the tool support 514 may include a rack or at least one flexible pull or strap 516. The use of the rack or strap provides a user with additional methods of securing desired tools, components, and work material to the air compressor assembly 500. Additionally, it is contemplated that an open box tool carrier molded out of plastic may be mounted to the pan support 512 wherein certain types of tools, components, and other supplies may be received. In even further exemplary embodiments, it is contemplated that the tool support 514 may include a hose reel assembly as shown in FIG. 1C. In such embodiment, the hose reel assembly allows at least one air compressor assembly hoses to be secured around the reel as well as for the storage of additional air compressor components (e.g. guns, nozzles, fittings, and the like) or necessary tools (e.g. wrenches, screwdrivers, etc.) and hardware (e.g. nails) for a specific job. For example, a user may equip the air compressor assembly with a hose and job specific tools and components prior to leaving for a job-site. All of the components are then transported with the compressor assembly ensuring that the user is able to commence work upon arrival and not wait for the separately transported components. The hose reel assembly may be formed of plastic, metal, and the like. Further, such assembly may be secured to the pan support 512 via welding or the use of fasteners including screws, nuts, bolts, and the like.

It is contemplated that the tool carrier of the present invention may be implemented within additional devices which require the use of a long connector and the ability to be mobile without departing from the scope and spirit of the present invention.

A portable air compressor assembly having a tool carrier in accordance with the present invention makes it possible to transport the portable air compressor assembly together with air compressor accessories such as hoses, nozzles, and the like, as well as other job-specific work material and tools. Thus, after being transported to a new worksite, the air compressor assembly is available for immediate operation without waiting for the arrival of air compressor accessories since the portable air compressor assembly and air compressor accessories (e.g. hoses, nozzles, and the like) are transported together.

It is believed that the present invention and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention of the following claims to encompass and include such changes. 

1. A tool carrier for an air compressor assembly, comprising: a pan support coupled to a frame of the air compressor assembly for providing a support surface for an air compressor accessory and work material; and a tool support coupled to the pan support for providing an additional support surface for the air compressor accessory and work material, the tool support including at least one strap, wherein the at least one strap allows the air compressor accessory and work material to be secured to the pan support.
 2. The tool carrier of claim 1, wherein the tool support includes a back support for providing additional support to the air compressor accessory and work material.
 3. The tool carrier of claim 1, wherein the tool support includes a rack for providing additional support to the air compressor accessory and work material.
 4. The tool carrier of claim 3, wherein the tool support includes a cover for providing additional support to the air compressor accessory and work material.
 5. The tool carrier of claim 1, wherein the at least one strap includes a system of flexible straps formed of material selected from the group consisting of plastic, rubber, nylon, vinyl, and hook and loop fastening material.
 6. The tool carrier of claim 5, wherein a nylon mesh material is coupled to the system of flexible straps for providing additional support to the air compressor accessory and work material.
 7. The tool carrier of claim 1, wherein the tool support includes a hose reel for securing the air compressor accessory and work material to the pan support.
 8. The tool carrier of claim 1, wherein the pan support is formed to include raised portions for providing additional support to the air compressor accessory and work material.
 9. The tool carrier of claim 1, wherein the air compressor assembly is a suitcase style assembly with the frame being a roll cage and including an extendable handle for transporting the air compressor assembly.
 10. The tool carrier of claim 1, wherein the air compressor assembly is a pancake style assembly with the frame being a dolly style frame.
 11. A portable air compressor assembly having a tool carrier, comprising: a air tank for storing compressed air; a compressor for supplying compressed air to the air tank; a frame coupled to the air tank and compressor for mounting the air tank and the compressor; a pair of wheels pivotally mounted to the frame allowing for inclined transportation of the air compressor assembly; a pan support coupled to the frame for providing a support surface for an air compressor accessory and work material; and a tool support coupled to the pan support for providing an additional support surface for the air compressor accessory and work material, the tool support including at least one strap, wherein the at least one strap allows the air compressor accessory and work material to be secured to the pan support.
 12. The portable air compressor assembly of claim 11, wherein the tool support includes a back support for providing additional support to the air compressor accessory and work material.
 13. The portable air compressor assembly of claim 1 1, wherein the tool support includes a rack for providing additional support to the air compressor accessory and work material.
 14. The portable air compressor assembly of claim 13, wherein the tool support includes a cover for providing additional support to the air compressor accessory and work material.
 15. The portable air compressor assembly of claim 11, wherein the at least one strap includes a system of flexible straps formed of material selected from the group consisting of plastic, rubber, nylon, vinyl, and hook and loop fastening material.
 16. The portable air compressor of claim 15, wherein a nylon mesh material is coupled to the system of flexible straps for providing additional support to the air compressor accessory and work material.
 17. The portable air compressor assembly of claim 11, wherein the tool support includes a hose reel for securing the air compressor accessory and work material to the pan support.
 18. The portable air compressor assembly of claim 11, wherein the pan support is formed to include raised portions for providing additional support to the air compressor accessory and work material.
 19. The portable air compressor assembly of claim 11, wherein the air compressor assembly is arranged as a suitcase style assembly with the frame being a roll cage and including an extendable handle for transporting the air compressor assembly.
 20. The tool carrier of claim 11, wherein the air compressor assembly is a pancake style assembly with the frame being a dolly style frame. 